BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a gas boiler, more particularly, to a method for
controlling a combustion state by using a flame voltage sensed by an infrared sensor
when gas combustion occurs.
2. Prior Art
[0002] An infrared sensor serves to detect a temperature of a flame generated at a burner
and generate a flame voltage corresponding to the temperature of the flame.
[0003] U.S. Patent No. 5,332,386(issued to Hosome Kazunari et al. on July 24, 1994) discloses
a combustion control method.
[0004] FIG. 1 shows a configuration of a conventional gas boiler. As shown in FIG. 1, the
conventional gas boiler includes a gas valve 104, a controller 105, a burner 106,
a spark plug 107, a water tank 114, a cross valve 116, a heat exchanger 118, a hot-water
feeding tube 120, a flow valve 130, and a cycle pump 132.
[0005] When gas is fed into a burner 106 by switching the gas valve 104, a spark generated
by the spark plug 107 lights the gas. Then, a flame is generated at the burner 106.
At this time, the infrared sensor 109 detects the temperature of the flame and outputs
combustion temperature corresponding to the temperature of the flame to the controller
105. That is, information of combustion is outputted to the controller 105.
[0006] A combustion gas of high temperature rises. The heat exchanger 118 is installed at
an upper part of the burner 106 through which the combustion gas flows to heat the
warm water and cold water. The warm water circulates in the heat exchanger 111. The
cold water, which goes through the cold water feeding tube 126, is heated in the heat
exchanger 118. As a result, both cold water and warm water are heated by the combustion
in the burner 106.
[0007] The cross valve 116 is controlled to circulate the warm water in a heating mode,
and to feed warm water in a hot-water mode. Detection of the hot-water mode is determined
by detecting the cold water being fed to the flow valve 130.
[0008] At the heating mode, the warm water heated by the heat exchanger 118 is fed to a
warm water tube (not shown) through the hot-water feeding tube 120. Then the warm
water is returned to the water tank 114 through the warm water return tube 112. The
warm water loses heat while the warm water flows through warm water tube (not shown).
The returned warm water is again fed to the heat exchanger 118 through the cross valve
116 and the cycle pump 132. The warm water being fed is again heated at the heat exchanger
118 and is outputted through the hot-water feeding tube 126. The cross valve 116 is
provided to control water flow. At the heating mode, the flow cycle of the warm water
includes the water tank 114 and the heat exchanger 118. Meanwhile, at the water warming
mode, the flow cycle of the warm water includes the cycle pump 132 and the heat exchanger
118.
[0009] With the conventional gas boiler, defective combustion or oxygen over-combustion
occurs due to some outside influences, that is, a forward wind or a reverse wind.
In addition, when the forward or reverse wind strengthens, the conventional gas boiler
is often extinguished. As a result, the life cycle of the conventional boiler is shortened.
Also, the warming operation malfunctions.
SUMMARY OF THE INVENTION
[0010] Therefore, it is an object of the present invention, for the purpose of solving the
above mentioned problems, to provide a combustion control method for a gas boiler
capable of maintaining a stable combustion state by using a flame voltage by means
of an infrared sensor.
[0011] In order to attain the object, according to the present invention, there is provided
a combustion control method for a gas boiler, said method comprising the steps of:
(a) judging whether a flame voltage is higher than a reference forward wind flame
voltage when combustion occurs in the gas boiler;
(b) firstly controlling a fan voltage when the flame voltage is higher than the reference
forward wind flame voltage and judging whether the flame voltage is lower than a reference
reverse wind flame voltage when the flame voltage is lower than or equal to the reference
forward wind flame voltage; and
(c) controlling the fan voltage when the flame voltage is lower than the reference
reverse wind flame voltage, and compensating the first controlled fan voltage to an
original fan voltage according to change amount of the fan voltage by the first control
of the fan voltage or the second control of the fan voltage when the flame voltage
is equal to or higher than the reference reverse wind flame voltage, in step (b).
[0012] Also, there is provided a combustion control method for a gas boiler,combustion control
method for a gas boiler, said method comprising the steps of:
(i) setting a forward wind sensing flag, a reverse wind sensing flag, and a fan voltage
change amount to a first logical value, the first logical value, and a predetermined
value, respectively;
(ii) judging whether the forward wind sensing flag is set to a second logical value
or whether a combustion flame voltage is higher than a reference forward wind combustion
voltage;
(iii) firstly controlling a combustion fan voltage when the forward wind sensing flag
is set to the second logical value or the combustion flame voltage is higher than
the reference forward wind combustion voltage, and judging whether the reverse wind
sensing flag is set to the second logical value or whether the combustion flame voltage
is lower than a reference reverse wind combustion voltage when the forward wind sensing
flag is set to the first logical value and the combustion flame voltage is lower than
or equal to the reference forward wind combustion voltage;
(iv) secondly controlling the combustion fan voltage when the reverse wind sensing
flag is set to the second logical value or the combustion flame voltage is lower than
the reference reverse wind combustion voltage, and compensating the combustion fan
voltage to an original fan voltage according to a fan voltage amount by the first
and second control of the combustion fan voltage when the reverse wind sensing flag
is set to the first logical value and the combustion flame voltage is equal to or
higher than the reference reverse wind combustion voltage.
[0013] According to the present invention, when a combustion is imperfect due to external
environment such a forward or reverse wind, it can maintain a stable combustion by
controlling a fan voltage. The present invention controls a control time of a fan
voltage to thereby control the flame voltage. The present invention has a variety
of change widths of a flame voltage by using both a reference flame voltage and a
threshold flame voltage to thereby maintain a stable combustion state sensitively.
[0014] Other objects and further features of the present invention will become apparent
from the detailed description when read in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Other features and advantages of the present invention will become more apparent
from the following description taken in connection with the accompanying drawings,
wherein:
FIG. 1 is a view, for showing a configuration of a conventional gas boiler;
FIG. 2 is a block diagram for showing a configuration of a combustion control apparatus
according to an embodiment of the present invention;
FIG. 3 is a graph for showing a combustion state according to the relationship between
a gas consumption amount and a flame voltage in accordance with a first embodiment
of the present invention;
FIG. 4 is a flow chart for illustrating a combustion control method according to the
first embodiment of the present invention;
FIG. 5 is a graph for showing a combustion state according to the relationship between
a gas consumption amount and a flame voltage in accordance with a second embodiment
of the present invention; and
FIG. 6 is a flow chart for illustrating a combustion control method according to the
second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] The preferred embodiment of the present invention will hereinafter be described in
detail with reference to the accompanying drawings.
[0017] FIG. 2 shows a configuration of a combustion control apparatus 20 according to an
embodiment of the present invention. The combustion control apparatus 20 includes
an infrared sensor 201, a controller 202, a memory 204, and a voltage control unit
206.
[0018] The infrared sensor 201 detects a temperature of a flame generated at a burner and
generates a flame voltage corresponding to the temperature of the flame.
[0019] The controller 202 judges whether a flame voltage is higher than a reference forward
wind flame voltage when combustion occurs in the gas boiler. The controller 202 firstly
controls a fan voltage when the flame voltage is higher than the reference forward
wind flame voltage and judges whether the flame voltage is lower than a reference
reverse wind flame voltage when the flame voltage is lower than or equal to the reference
forward wind flame voltage, in the step. The controller 202 controls the fan voltage
when the flame voltage is lower than the reference reverse wind flame voltage, and
compensates the first controlled fan voltage to an original fan voltage according
to the change amount of the fan voltage by the first control of the fan voltage or
the second control of the fan voltage when the flame voltage is equal to or higher
than the reference reverse wind flame voltage. The memory 204 stores the change amount
of the fan voltage by the first or second control of the fan voltage under of the
controller 202. The voltage control unit 206 adjusts a fan voltage which is applied
to the fan 200 under control of the controller 202.
[0020] FIG. 3 is a graph for showing a combustion state according to the relationship between
a gas consumption amount and a flame voltage in accordance with a first embodiment
of the present invention. The flame voltage Vc is defined as the voltage which is
transferred from the temperature of the flame generated during the combustion. In
general, the flame voltage varies according to the color variance of the flame being
generated during the combustion. In an embodiment of the present invention, the flame
voltage preferably ranges from 0 to 5 volts. As shown in FIG. 3, at a predetermined
gas consumption amount, the excess combustion voltage indicates that the present combustion
situation is in the forward wind situation. However, the deficient combustion voltage
indicates that the present combustion situation is in the reverse wind situation.
The forward wind situation is defined as the situation that too much air is supplied
so that oxygen-over combustion occurs. The reverse wind situation is defined as the
situation that some exhaust gas flows backward so that incomplete combustion occurs.
The normal combustion region shown in FIG. 3 is divided by the upper combustion voltage
line (Vfmax) and the lower combustion voltage line (Vfmin).
[0021] Hereinafter, the combustion control method according to the first embodiment of the
present invention will be described referring to FIG. 4. FIG. 4 is a flow chart for
illustrating a combustion control method according to the first embodiment of the
present invention.
[0022] In step S401, the controller 202 judges whether or not a combustion flame voltage
Vf sensed by an infrared sensor 201 is higher than a reference forward wind voltage
Vfmax for 2 seconds when combustion occurs in the gas boiler.
[0023] As a result of the judgement in step S401, when the combustion flame voltage Vf is
higher than the reference forward wind voltage Vfmax, the controller 202 judges that
a present combustion of gas boiler is in a forward state and controls a voltage control
unit 206 to subtract an alternating current power(AC) 10 volts from a combustion fan
voltage V
F (step S402). Then the controller 202 controls a memory 204 to store a fan voltage
change amount ΔV
F with respect to the combustion fan voltage Vf according to subtraction of step S402(step
S403). Then the routine returns to step S401.
[0024] To the contrary, when it is judged that the combustion flame voltage Vf is lower
than or equal to the reference forward wind voltage Vfmax, the controller 202 judges
whether or not the combustion flame voltage Vf is lower than a reference reverse wind
voltage Vfmin for 2 seconds (step S404).
[0025] As a result of the judgement in step S404, when the combustion flame voltage Vf is
lower than the reference reverse wind voltage Vfmin, the controller 202 judges that
a combustion of gas boiler is in a reverse wind state and controls a voltage control
unit 206 to add an alternating current power(10 volts) to the combustion fan voltage
V
F (step S405). Then the controller 202 controls a memory 204 to store a voltage change
amount ΔV
F with respect to the combustion fan voltage V
F according to the addition of step S405 (step S406). Then the routine returns to step
S401.
[0026] To the contrary, when it is judged that the combustion flame voltage Vf is equal
to or higher than the reference reverse wind voltage Vfmin, that is, when Vfmin ≤
Vf ≤ Vfmax, the controller 202 judges that a combustion of gas boiler is a normal
state and judges whether a voltage change amount ΔV
F which is stored in memory 204 is zero(step S407).
[0027] As a result of the judgement in step S407, when the stored voltage change amount
ΔV
F is zero, the routine returns to step S401. When it is judged that the stored voltage
change amount ΔV
F is not zero in step S407, the controller 202 judges whether or not the stored voltage
change amount ΔV
F is larger than zero (step S408).
[0028] As a result of the judgement in step S408, the controller 202 controls the voltage
control unit 206 to subtract the voltage change amount ΔV
F from the combustion fan voltage V
F(step S409). That is, since it is judged the present combustion of the gas boiler
is in a reverse wind state in step S404 so that an AC 10 volts is added to the combustion
fan voltage V
F in step S405, the combustion fan voltage V
F increased in the reverse wind state is compensated by the voltage change amount ΔV
F in step S409. When it is judged that the stored voltage change amount ΔVf is less
than zero in step S408, the controller 202 adds the voltage change amount ΔVf to the
combustion fan voltage V
F. That is, since it is judged the combustion of the gas boiler is in a forward wind
state in step S401 so that an AC 10 volts is subtracted from the combustion fan voltage
V
F in step S402, the combustion fan voltage V
F reduced in the forward wind state is compensated by the voltage change amount ΔV
F in step S410. After performing step S409 or step S410, the routine returns to step
S401.
[0029] FIG. 5 is a graph for showing a combustion state according to the relationship between
a gas consumption amount and a flame voltage in accordance with a second embodiment
of the present invention. The flame voltage Vc is defined as the voltage which is
transferred from the temperature of the flame generated during the combustion. In
general, the flame voltage varies according to the color variance of the flame being
generated during the combustion. In an embodiment of the present invention, the flame
voltage preferably ranges from 0 to 5 volts. As shown in FIG. 5, at a predetermined
gas consumption amount, the excess combustion voltage indicates that the present combustion
situation is in the forward wind situation. However, the deficient combustion voltage
indicates that the present combustion situation is in the reverse wind situation.
The forward wind situation is defined as the situation that too much air is supplied
so that oxygen over-combustion occurs. The reverse wind situation is defined as the
situation that some exhaust gas flows backward so that incomplete combustion occurs.
The normal combustion region shown in FIG. 5 is divided by the upper combustion voltage
line (Vfmax) and the lower combustion voltage line (Vfmin). V
FT and V
RT are forward and reverse wind threshold flame voltages, respectively. In an embodiment
of the present invention, preferably,

and

.
[0030] Hereinafter, the combustion control method according to the second embodiment of
the present invention will be described referring to FIG. 6. FIG. 6 is a flow chart
for illustrating a combustion control method according to the second embodiment of
the present invention.
[0031] In step S601, the controller 202 sets a forward wind sensing flag F
f and a reverse wind sensing flag F
r to "0" and sets a fan voltage change amount ΔV
F to zero volts. In an embodiment of the present invention, when a combustion flame
voltage Vf < a forward wind threshold flame voltage V
FT, a forward wind sensing flag F
f is set to a first logical value, that is, "0", and when Vf ≥ V
FT, a forward wind sensing flag F
f is set to a second logical value, that is, "1". Also, when a combustion flame voltage
Vf > a reverse wind threshold flame voltage V
RT, a reverse wind sensing flag F
r is set to "0" and when Vf ≤ V
RT, a reverse wind sensing flag F
r is set to "1".
[0032] In step S602, the controller 202 judges whether or not a forward wind sensing flag
F
f is set to "1" or whether or not a combustion flame voltage Vf sensed by an infrared
sensor 201 is higher than a reference forward wind flame voltage Vfmax for 2 seconds
when combustion occurs in the gas boiler.
[0033] As a result of the judgement in step S602, when the forward wind sensing flag F
f is set to "1" or the combustion flame voltage Vf is higher than the reference forward
wind flame voltage Vfmax, the controller 202 judges that a combustion of gas boiler
is in a forward wind state and judges whether or not the combustion flame voltage
Vf is lower than or equal to a forward wind threshold flame voltage V
FT (step S603).
[0034] As a result of the judgement in step S603, when the combustion flame voltage Vf is
lower than or equal to the forward wind threshold flame voltage V
FT, the controller 202 sets the forward wind sensing flag F
f to "0" (step S604) and the routine returns to step S602. To the contrary, when it
is judged that the combustion flame voltage Vf is higher than the forward wind threshold
flame voltage V
FT in step S603, the controller 202 sets the forward wind sensing flag F
f to "1", controls a voltage control unit 206 to subtract an alternating current power(AC)
10 volts from a combustion fan voltage V
F, controls the voltage control unit 206 to subtract a voltage of 10 volts from the
fan voltage change amount ΔV
F set in step S601 and stores the subtracted fan voltage change amount in the memory
204(step S605). Then the routine returns to step S602.
[0035] To the contrary, when it is judged the forward wind sensing flag F
f is set to "0" and the combustion flame voltage Vf is lower than or equal to the reference
forward wind flame voltage Vfmax, the controller 202 judges whether or not a reverse
wind sensing flag F
r is set to "1" or whether or not the combustion flame voltage Vf is lower than a reference
reverse wind voltage Vfmin for 2 seconds when combustion occurs in the gas boiler
(step S606).
[0036] As a result of the judgement in step S606, when the reverse wind sensing flag F
r is set to "1" or the combustion flame voltage Vf is lower than the reference reverse
wind voltage Vfmin, the controller 202 judges that the combustion of gas boiler is
in a reverse wind state and judges whether or not the combustion flame voltage Vf
is equal to or higher than a reverse wind threshold flame voltage V
RT (step S607).
[0037] As a result of the judgement in step S607, when the combustion flame voltage Vf is
higher than or equal to the reverse wind threshold flame voltage V
RT, the controller 202 sets the reverse wind sensing flag F
r to "0" (step S608) and the routine returns to step S602. To the contrary, when it
is judged that the combustion flame voltage Vf is higher than the forward wind threshold
flame voltage V
FT in step S607, the controller 202 sets the reverse wind sensing flag F
r to "1", controls a voltage control unit 206 to add an AC power of 10 volts to the
combustion fan voltage V
F, controls the voltage control unit 206 to add a voltage of 10 volts to the fan voltage
change amount ΔV
F set in step S601 and stores the added fan voltage change amount in the memory 204
(step S609). Then the routine returns to step S602.
[0038] To the contrary, when it is judged that the reverse wind sensing flag F
r is set to "0" and the combustion flame voltage Vf is equal to or higher than the
reference reverse wind voltage Vfmin (that is, V
RT ≤ Vf ≤ Vfmax), the controller 202 judges that the combustion of gas boiler is in
a normal state and judges whether a voltage change amount ΔVf which is stored in memory
204 is zero volt (step S610).
[0039] As a result of the judgement in step S610, when the stored voltage change amount
ΔV
F is zero volt, the routine returns to step S602. When it is judged that the stored
voltage change amount ΔV
F is not zero in step S610, the controller 202 judges whether or not the stored voltage
change amount ΔV
F is higher than zero volts (step S611).
[0040] As a result of the judgement in step S611, when the stored fan voltage change amount
ΔV
F is lower than zero volt, the controller 202 judges whether or not the combustion
flame voltage Vf is lower than or equal to a forward wind threshold flame voltage
V
FT(step S612).
[0041] As a result of the judgement in step S612, when the combustion flame voltage Vf is
lower than or equal to the forward wind threshold flame voltage V
FT, the controller 202 controls the voltage control unit 206 to add a voltage of AC
10 volts to the combustion fan voltage V
F to thereby compensate the fan voltage change amount reduced in step S605 by it, and
adds a voltage of 10 volts to the stored fan voltage change amount (step S613).
[0042] That is, it is judged that the combustion of the gas boiler is in the forward wind
state in step S602 and the combustion flame voltage Vf is higher than the forward
wind threshold flame voltage V
FT in step S603, so that a voltage of AC 10 volts is subtracted from the combustion
flame voltage Vf in step S605. Then it is judged that the stored fan voltage change
amount ΔV
F is lower than zero volt and the combustion flame voltage Vf in step S612 is lower
than or equal to the forward wind threshold flame voltage V
FT. Accordingly, in step S613, a voltage corresponding to the fan voltage change amount
reduced in step S605 is compensated . Then 1 second passes (step S614) and the routine
returns to step S602.
[0043] To the contrary, when it is judged that the combustion flame voltage Vf is higher
than the forward wind threshold flame voltage V
FT in step S612, the controller 202 judges that V
FT ≤ Vf ≤ Vfmax and adds a voltage of AC 5 volts to the combustion flame voltage Vf
so that the fan voltage change amount reduced in step S605 is compensated by a half
thereof, and adds a voltage of 5 volts to the fan voltage change amount ΔV
F (step S615).
[0044] That is, it is judged that the combustion of the gas boiler is in the forward wind
state in step S602 and the combustion flame voltage Vf is higher than the forward
wind threshold flame voltage V
FT, so that a voltage of AC 10 volts is subtracted from the combustion flame voltage
Vf in step S605. Then it is judged that the stored fan voltage change amount ΔV
F is lower than zero volt step S611 and the combustion flame voltage Vf in step S612
is higher than the forward wind threshold flame voltage V
FT. Accordingly, in step S615, a half by a half of a voltage corresponding to the fan
voltage change amount reduced in step S605 is gradually compensated. In other words,
since V
FT ≤ Vf ≤ Vfmax in step S612, the combustion fan voltage reduced in step S605 is gradually
compensated by a half by a half of the reduced fan voltage change amount. Then 2 seconds
pass (step S616) and the routine returns to step S602.
[0045] As a result of the judgement in step S611, when the stored fan voltage change amount
ΔV
F is higher than zero volt, the controller 202 judges whether or not the combustion
flame voltage Vf is equal to or higher than the reverse wind threshold flame voltage
V
RT(step S617).
[0046] As a result of the judgement in step S617, when the combustion flame voltage Vf is
equal to or higher than the reverse wind threshold flame voltage V
RT, the controller 202 controls the voltage control unit 206 to subtract a voltage of
AC 5 volts from the combustion fan voltage V
F to thereby compensate the fan voltage change amount increased in step S609 by it,
and subtracts a voltage of 10 volts from the stored fan voltage change amount(step
S618).
[0047] That is, it is judged that the combustion of the gas boiler is in the reverse wind
state in step S602 and the combustion flame voltage Vf is lower than the reverse wind
threshold flame voltage V
RT in step S607, so that a voltage of AC 10 volts is added to the combustion flame voltage
Vf in step S609. Then it is judged that the stored fan voltage change amount ΔV
F is higher than zero volt in step S611 and the combustion flame voltage Vf in step
S617 is equal to or higher than the reverse wind threshold flame voltage V
RT. Accordingly, in step S618, a voltage corresponding to the fan voltage change amount
increased in step S609 is compensated. Then 1 second is passed (step S619) and the
routine returns to step S602.
[0048] To the contrary, when it is judged that the combustion flame voltage Vf is lower
than the reverse wind threshold flame voltage V
RT in step S617, the controller 202 judges that Vfmin ≤ Vf ≤ V
RT and subtracts a voltage of AC 5 volts from the combustion flame voltage Vf so that
the fan voltage change amount increased in step S605 is compensated by a half thereof,
and subtracts a voltage of 5 volts to the fan voltage change amount ΔV
F (step S620).
[0049] That is, it is judged that the combustion of the gas boiler is in the reverse wind
state in step S606 and the combustion flame voltage Vf is lower than the reverse wind
threshold flame voltage V
RT in step S607 so that a voltage of AC 10 volts is added to the combustion flame voltage
Vf in step S609. Then it is judged that the stored fan voltage change amount ΔV
F is higher than zero volt in step S611 and the combustion flame voltage Vf in step
S617 is lower than the reverse wind threshold flame voltage V
RT. Accordingly, in step S620, a half by a half of a voltage corresponding to the fan
voltage change amount increased in step S609 is gradually compensated. In other words,
since Vfmin ≤ Vf ≤ V
RT in step S617, the combustion fan voltage increased in step S609 is gradually compensated
by a half by a half of the reduced fan voltage change amount. Then 2 seconds are passed(step
S621) and the routine returns to step S602.
[0050] In accordance with the present invention, when a combustion is imperfect due to external
environment such a forward or reverse wind, it can maintain a stable combustion by
controlling a fan voltage. The present invention controls a control time of a fan
voltage to thereby control the flame voltage. The present invention has a variety
of change widths of a flame voltage by using both a reference flame voltage and a
threshold flame voltage to thereby maintain a stable combustion state sensitively.
[0051] The invention may be embodied in other specific forms without departing from the
spirit or essential characteristics thereof. The present embodiments are therefore
to be considered in all respects as illustrative and not restrictive, the scope of
the invention being indicated by the appended claims rather than by the foregoing
description and all changes which come within the meaning and range of equivalency
of the claims are therefore intended to be embraced therein.